Remove/install distributor injection pump

AR07.13-D-8410A

Remove/install distributor injection pump

7.9.15

Engine

602.980 in model 901, 902, 903, 904

1

injection pump

2

Washer

3

Nut

4

Injection lines

5

Screw/bolt

6

Screw/bolt

7

Bracket

8

Bracket

9

Supporting bracket

10

Screw/bolt

11

Washer

12

Washer

13

Screw/bolt

14

Fuel feed line

15

Fuel return line

16

Drive plate with race

17

Nut

18

Woodruff key

 

Remove/install

1

Disconnect ground line of battery

2

Remove cylinder head cover

AR01.20-D-5014A

3

Position engine at 12° before ignition TDC of cylinder 1

 Check whether both cams of the camshaft on cylinder 1 point upwards.

4

Detach fuel lines (14, 15 ) to the injection pump (1)

 Injection lines to injection nozzle/injection pump

*BA07.13-N-1001-01A

5

Close off electrical lines for distributor injection pumps

AR07.13-D-8410-03A

6

Remove injection lines (4)

AR07.13-D-9230-01A

 Injection lines to injection nozzle/injection pump

*BA07.13-N-1001-01A

 Bolts, bracket of injection lines to intake manifold

*BA07.13-N-1007-01A

 Bolts, injection lines bracket to support

*BA07.13-N-1010-01A

7

Unscrew screw/bolt (10) with washer (11) on supporting bracket (9) and support on injection pump (1) at the rear

 Bolts, support to injection pump

*BA07.13-N-1009-01A

8

Unscrew screw/bolts (13) with washer (12) from crankcase and remove supporting bracket (9)

 Bolts, support to cylinder crankcase

*BA07.13-N-1008-01A

9

Detach injection pump (1) on intermediate flange

 For pulling out observe the coupling sleeve.

 Nut, injection pump to intermediate flange

*BA07.13-N-1002-01A

10

Modify drive plate (16) for distributor fuel injection pump

AR07.13-D-8410-04A

 Only when injection pump is replaced.

 Nut, drive plate to injection pump

*BA07.13-N-1005-01A

 Holding wrench

*602589000700

 Puller

*602589013300

11

Check radial shaft sealing ring intermediate flange

replace if necessary, see:



Removing and installing radial shaft seal of intermediate flange

AR07.13-D-8420-02A

12

Adjust basic setting for distributor fuel injection pump

AR07.13-D-8410-02A

13

Install in the reverse order

 In order to simplify starting the engine, remove connection fitting from fuel return and fill the distributor injection pump before installation with about 0.2 liters of clean diesel fuel.

14

Adjust start of injection with HHT

AR07.13-D-8430A

Do not start the engine after assembly:



Open and purge injection line to cylinder 1 for a short time

 Distributor injection pump

Number

Designation

Engine 602.980

BA07.13-N-1001-01A

Injection lines to injection nozzle/injection pump

Nm

18

 Distributor injection pump

Number

Designation

Engine 602.980

BA07.13-N-1002-01A

Nut, injection pump to intermediate flange

Nm

23

 Distributor injection pump

Number

Designation

Engine 602.980

BA07.13-N-1005-01A

Nut, drive plate to injection pump

Nm

83

 Distributor injection pump

Number

Designation

Engine 602.980

BA07.13-N-1007-01A

Bolts, bracket of injection lines to intake manifold

Nm

10

 Distributor injection pump

Number

Designation

Engine 602.980

BA07.13-N-1008-01A

Bolts, support to cylinder crankcase

Nm

10

 Distributor injection pump

Number

Designation

Engine 602.980

BA07.13-N-1009-01A

Bolts, support to injection pump

Nm

15

 Distributor injection pump

Number

Designation

Engine 602.980

BA07.13-N-1010-01A

Bolts, injection lines bracket to support

Nm

10